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Home >> Pontiac >> 2002 >> Aztek AWD >> Repair and Diagnosis >> Engine Mechanical >> Engine Exhaust System >> Repair Instructions >> Exhaust Manifold Replacement - Right >> Installation Procedure
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Installation Procedure

  1. If removed, install the Heated Oxygen Sensor (HO2S). Refer to HEATED OXYGEN SENSOR .
  2. If removed, install the exhaust gas recirculation (EGR) valve pipe.
  3. Raise and support the vehicle. Refer to LIFTING AND JACKING THE VEHICLE .
  4. Install the exhaust manifold gasket.
  5. Install the exhaust manifold.
    NOTE: Refer to FASTENER NOTICE .
  6. Install the exhaust manifold nuts.

    Tighten 

    Tighten the exhaust manifold nuts to 16 N.m (12 lb ft).

    Fig 1: Installing Exhaust Manifold, Gasket & Nuts
    G01747742Courtesy of GENERAL MOTORS CORP.
  7. Install the exhaust manifold lower heat shield.
  8. Install the exhaust manifold upper heat shield.
  9. Install the exhaust manifold heat shield bolts.

    Tighten 

    Tighten the exhaust manifold heat shield bolts to 10 N.m (89 lb in).

  10. Install the catalytic converter. Refer to Catalytic Converter Replacement .
  11. Lower the vehicle.
  12. Install the exhaust crossover pipe. Refer to Exhaust Crossover Pipe Replacement .
  13. Install the exhaust crossover pipe heat shield. Refer to Exhaust Crossover Pipe Replacement .
  14. Connect the Heated Oxygen Sensor (HO2S) electrical connector.
    Fig 2: Installing Exhaust Manifold Heat Shields & Bolts
    G01747743Courtesy of GENERAL MOTORS CORP.
  15. Install the EVAP solenoid bracket.
  16. Install the spark plug wires to the engine right bank spark plugs.
  17. Install the ignition module and the ignition coils with the bracket.
  18. Rotate the engine back to the original position. Refer to ROTATING THE ENGINE FOR SERVICE ACCESS .
  19. Install the EGR valve to the intake manifold. Refer to EGR VALVE .
  20. Install the MAP sensor. Refer to MANIFOLD ABSOLUTE PRESSURE SENSOR .
  21. Install the accelerator cable bracket to the throttle body. Refer to ACCELERATOR CONTROLS CABLE BRACKET .
  22. Install the throttle body air inlet duct.
  23. Connect negative battery cable. Refer to BATTERY NEGATIVE CABLE DISCONNECT/CONNECT PROCEDURE .
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